Carry this modification at your own risk.

Parts needed, from your local electronics shop.

A> 2X variable 0 to 1k ohm resistor 50VAC rated 0.05W or more, or available on line here

B> 2 different colour electrical wire. I used red & yellow. 2mm thick by 1200mm for each length.

C> Soldering iron, solder & a length of heat shrink 3mm thick core.

* * * FITTING INSTRUCTIONS * * *

1> Remove seat & both side covers. Ignition switch off & key removed from bike

2> Locate Coolant Temp Sender, right side of cylinder head. Follow the loom back from the sender, to just under the fuel tank

3> Cut the GREEN/RED wire. Then solder the RED wires to each end of the cut wires. Use heat shrink to seal the joints.

Fig 1

4> Run the red wires back over the air box to the tool kit. Now cut the red wire in two. Then solder the variable resistor to each end of the red wires. Seal with heat shrink.

Fig 2

Fig 3

Fig 4

5> The Coolant circuit is now complete.

6> On the left side of the air box towards the front of the air box, you will find the Air Temp Sender.

7> You will find a 2 pin connector at the air temp sender. Cut the BLACK/BLUE wire in half a few cm’s away from the plug. Solder the Yellow wires to the end of the BLACK/BLUE wires & seal with heat shrink.

Fig 5

Fig 6

8> Run the yellow wires back over the air box to the tool kit. Now cut the yellow wires in two. Then solder the second variable resistor to each end of the red wires. Seal with heat shrink

Fig 7

Fig 8

9> Refit side covers back on bike.

10> You are now ready to set the adjustment of the resistors.

11> Hold in the select & reset buttons on your dash at the same time, turn on the ignition key. Hold the buttons in until Diag is displayed. Let go buttons. Push & hold both buttons again. Until 01 & a number is displayed, this is the throttle angle. Push the select button until 05 & a number is displayed. This is the Air Temp reading, now adjust the temp down using the variable resister by 5 deg C from the displayed reading.


Push the select button again, until 06 & a number is displayed. This is the Coolant Temp reading. Adjust the temp by using the 2nd variable resister to read 5deg C below the displayed reading. Warning the temp sender also runs the coolant fan so the adjustment should not be lowered below the 5 deg C setting. You are able to adjust the Air temp sender to any setting. I found 5deg C to be the best mixture for my bike for both settings. Important ride the bike & get it up to running temp, go back & fine tune the settings again. Settings must be set at operational temp.I also adjusted my throttle angle in 01 from 16 to 22. My CO was adjusted richer from 9 to 33. The air box snorkel was removed. Std pipes & a K&N filter.

The Kev Mod is now available for purchase on eBay

Thank you Kev for providing us with this very handy tip -

The Capt.

=============================================

06 Jan 2007 Latest development of the Kev Mod

Written by Kev Hope

Today I had some mates around to my house to run their XTX's on the Dyno. The results after 19 runs, good to know mates that own their own Dyno Jet Dyno.

Kev's bike 2004.

Kev Fuel & airbox Mod, DNA stage 1 & 2 & a set of Carbon Cans. Snorkel removed

45 HP STD to 50.4 HP = 5.4HP gain 12% over STD.

43.2 to 47.5 ft-lbs of torque = 4.3 ft-lbs gain 10.5% over STD

Kens Bike brand new bike 2006, 62kms on the clock. Being brand new I would expect 1 to 1.5 HP more from the motor once run in.

Kev Fuel & Airbox mod & DNA stage 1 & 2 filters. Snorkel removed.

44.8HP to 48.1HP = 3.3HP gain 7.3% over STD

43.1 to 46.9 ft-lbs torque = 3.8 ft-lbs gain 9% over STD

Dan's race bike 2005. Total price of mods AUD$ 60.00

Kev's Fuel & Airbox mod, STD filter paper cut out to leave gauze only, three extra holes in side box cover. STD pipe mod, removed end plates on STD pipes, knocked a 20mm hole through the Cat & refitted the end plates.

45HP to 51.4HP = 6.4HP gain 14.2% over STD

43.0 to 48.1 ft-lbs of torque = 5.1 ft-lbs gain 12% over STD

45.0HP STD
47.1HP snorkel removed & STD pipe mod.
51.4HP Kev mod, filter mod, STD pipe mod.3 extra holes in side cover.

We are planing more dyno runs in 2 week time & will play with Dan's bike as he wants more power. I still think we can get more power from that airbox, this motor realy wants more air & fuel.

It's very hard to compare bike HP's on paper, done at different sea levels with different ambient temp & altitudes with correction factors. The only true way to know for sure if there is any gain is a before & after Dyno run.

Will keep you posted.
Kev

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